Compliant mechanism for suspension height sensor

Abstract

A compliant mechanism is provided for monitoring the position of a suspension of a vehicle. The compliant mechanism can include a body for coupling to both an angle sensor and the suspension of the vehicle. The body can have at least two first portions and at least one second portion. The second portion is coupled to both of the two first portions and is more flexible than the two first portions.

What is claimed: 
     
       1. A compliant mechanism for monitoring the position of a suspension of a vehicle, comprising:
 at least a first link and a second link, both of the first and second links forming at least a portion of the compliant mechanism, 
 the first link having a body, a first end and a second end, the first end being configured for securement to a sensor attached to a frame of the vehicle, the sensor being configured to monitor angular position of the first link relative to the frame, the second end having an engagement structure, 
 the second link having a body, a first end and a second end, the first end having an engagement structure; and 
 a flexible joint coupled to both the engagement structure of the first link and the engagement structure of the second link so as to allow relative movement between the first and second links; 
 wherein the engagement structures of the first and second links are formed as grooves; and 
 wherein the flexible joint has a body, a first end and a second end, the first and second ends having shapes complementary to the grooves in the first and second links. 
 
     
     
       2. The compliant mechanism of  claim 1 , wherein the first and second links are more rigid than the flexible joint. 
     
     
       3. The compliant mechanism of  claim 1 , wherein the first and second links are plastic. 
     
     
       4. The compliant mechanism of  claim 1 , wherein the flexible joint is rubber. 
     
     
       5. The compliant mechanism of  claim 1 , wherein the flexible joint is over molded with the first and second links. 
     
     
       6. The compliant mechanism of  claim 1  wherein the body of the second link comprises one or more recesses to reduce a mass of the second link. 
     
     
       7. The compliant mechanism of  claim 1 , wherein the second end of the second link comprises an engagement structure, and the compliant mechanism further comprising,
 a third link, the third link having a body, a first end and a second end, the first end of the third link being configured for securement to the suspension of the vehicle, the second end of the third link having an engagement structure; and 
 a second flexible joint coupled to both the engagement structure of the second link and the engagement structure of the third link so as to allow relative movement between the second and third links. 
 
     
     
       8. The compliant mechanism of  claim 7 , wherein the second and third links are more rigid than the second flexible joint. 
     
     
       9. The compliant mechanism of  claim 7 , wherein the third link is plastic. 
     
     
       10. The compliant mechanism of  claim 7 , wherein the second flexible joint is rubber. 
     
     
       11. The compliant mechanism of  claim 7 , wherein the second flexible joint is over molded with the second and third links. 
     
     
       12. The compliant mechanism of  claim 7 , wherein the engagement structures of the second end of the second link and the second end of the third link are formed as grooves. 
     
     
       13. The compliant mechanism of  claim 12 , wherein the second flexible joint has a body, a first end and a second end, the first and second ends having shapes complementary to the grooves in the second end of the second link and the second end of the third link. 
     
     
       14. The compliant mechanism of  claim 1 , wherein the sensor is an angle sensor. 
     
     
       15. The compliant mechanism of  claim 1 , wherein the sensor is a Hall-effect type sensor. 
     
     
       16. A compliant mechanism for monitoring a position of a suspension of a vehicle, comprising:
 a body configured to be coupled to both an angle sensor and the suspension of the vehicle, the body comprising at least two first portions and at least one second portion, the at least one second portion being coupled to both of the at least two first portions, the at least one second portion being more flexible than the at least two first portions, wherein a coupling between the at least two first portions and the at least one second portion includes an engagement structure formed as a groove in an end of one of the at least two first portions for engaging with a complementary shaped end of the at least one second portion. 
 
     
     
       17. The compliant mechanism of  claim 16 , wherein the at least two first portions include plastic and the at least one second portion includes rubber. 
     
     
       18. A compliant mechanism for monitoring the position of a suspension of a vehicle, comprising:
 at least a first link and a second link, both of the first and second links forming at least a portion of the compliant mechanism, 
 the first link having a body, a first end and a second end, the first end being configured for securement to a sensor attached to a frame of the vehicle, the sensor being configured to monitor angular position of the first link relative to the frame, the second end having an engagement structure, 
 the second link having a body, a first end and a second end, the first end having an engagement structure; and 
 a flexible joint coupled to both the engagement structure of the first link and the engagement structure of the second link so as to allow relative movement between the first and second links, wherein the flexible joint includes rubber. 
 
     
     
       19. A compliant mechanism for monitoring the position of a suspension of a vehicle, comprising:
 at least a first link and a second link, both of the first and second links forming at least a portion of the compliant mechanism, 
 the first link having a body, a first end and a second end, the first end being configured for securement to a sensor attached to a frame of the vehicle, the sensor being configured to monitor angular position of the first link relative to the frame, the second end having an engagement structure, 
 the second link having a body, a first end and a second end, the first end having an engagement structure; and 
 a flexible joint coupled to both the engagement structure of the first link and the engagement structure of the second link so as to allow relative movement between the first and second links, wherein the flexible joint is over molded with the first and second links. 
 
     
     
       20. A compliant mechanism for monitoring the position of a suspension of a vehicle, comprising:
 at least a first link and a second link, both of the first and second links forming at least a portion of the compliant mechanism, 
 the first link having a body, a first end and a second end, the first end being configured for securement to a sensor attached to a frame of the vehicle, the sensor being configured to monitor angular position of the first link relative to the frame, the second end having an engagement structure, 
 the second link having a body, a first end and a second end, the first end having an engagement structure; and 
 a flexible joint coupled to both the engagement structure of the first link and the engagement structure of the second link so as to allow relative movement between the first and second links; 
 wherein the second end of the second link comprises an engagement structure, and the complaint mechanism further comprising, 
 a third link, the third link having a body, a first end and a second end, the first end of the third link being configured for securement to the suspension of the vehicle, the second end of the third link having an engagement structure; and 
 a second flexible joint coupled to both the engagement structure of the second link and the engagement structure of the third link so as to allow relative movement between the second and third links, 
 wherein the engagement structures of the second end of the second link and the second end of the third link are formed as grooves; and 
 wherein the second flexible joint has a body, a first end and a second end, the first and second ends having shapes complementary to the grooves in the second end of the second link and the second end of the third link. 
 
     
     
       21. A compliant mechanism for monitoring the position of a suspension of a vehicle, comprising:
 at least a first link and a second link, both of the first and second links forming at least a portion of the compliant mechanism, 
 the first link having a body, a first end and a second end, the first end being configured for securement to a sensor attached to a frame of the vehicle, the sensor being configured to monitor angular position of the first link relative to the frame, the second end having an engagement structure, 
 the second link having a body, a first end and a second end, the first end having an engagement structure; and 
 a flexible joint coupled to both the engagement structure of the first link and the engagement structure of the second link so as to allow relative movement between the first and second links; 
 wherein the second end of the second link comprises an engagement structure, and the compliant mechanism further comprising, 
 a third link, the third link having a body, a first end and a second end, the first end of the third link being configured for securement to the suspension of the vehicle, the second end of the third link having an engagement structure; and 
 a second flexible joint coupled to both the engagement structure of the second link and the engagement structure of the third link so as to allow relative movement between the second and third links, wherein the second flexible joint includes rubber. 
 
     
     
       22. A compliant mechanism for monitoring the position of a suspension of a vehicle, comprising:
 at least a first link and a second link, both of the first and second links forming at least a portion of the compliant mechanism, 
 the first link having a body, a first end and a second end, the first end being configured for securement to a sensor attached to a frame of the vehicle, the sensor being configured to monitor angular position of the first link relative to the frame, the second end having an engagement structure, 
 the second link having a body, a first end and a second end, the first end having an engagement structure; and 
 a flexible joint coupled to both the engagement structure of the first link and the engagement structure of the second link so as to allow relative movement between the first and second links; 
 wherein the second end of the second link comprises an engagement structure, and the compliant mechanism further comprising, 
 a third link, the third link having a body, a first end and a second end, the first end of the third link being configured for securement to the suspension of the vehicle, the second end of the third link having an engagement structure; and 
 a second flexible joint coupled to both the engagement structure of the second link and the engagement structure of the third link so as to allow relative movement between the second and third links, wherein the second flexible joint is over molded with the second and third links. 
 
     
     
       23. A compliant mechanism for monitoring the position of a suspension of a vehicle, comprising:
 at least a first link and a second link, both of the first and second links forming at least a portion of the compliant mechanism, 
 the first link having a body, a first end and a second end, the first end being configured for securement to a sensor attached to a frame of the vehicle, the sensor being configured to monitor angular position of the first link relative to the frame, the second end having an engagement structure; 
 the second link having a body, a first end and a second end, the first end having an engagement structure; and 
 a separate flexible joint, made from a flexible material, interposed between the first link and the second link coupling the engagement structure of the first link to the engagement structure of the second link so as to allow relative movement between the flexibly coupled engagement structures of the first and second links through flexing of the flexible joint.